Conformal coating of cells for immunoisolation

ABSTRACT

Hydrodynamic methods for conformally coating non-uniform size cells and cell clusters for implantation, thus preventing immune rejection or inflammation or autoimmune destruction while preserving cell functionality. A method for conformally coating cells and c clusters with hydrogels that are biocompatible, mechanically and chemically stable and porous, with an appropriate pore cut-off size. The methods of the invention are advantageously reproducible and result in a relatively high yield of coated versus non-coated cell clusters, without compromising cell functionality. Conformal coating devices configured to perform the methods of the invention, methods of optimally utilizing said devices and purifying the coated islets, and coated biomaterials made by said methods.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/528,442 (now U.S. Pat. No. 11,623,021), filed Nov. 17, 2021, which isa divisional of U.S. patent application Ser. No. 16/847,220, filed Apr.13, 2021 (now U.S. Pat. No. 11,207,444), which is a continuation of U.S.patent application Ser. No. 14/114,690, filed Feb. 12, 2014 (now U.S.Pat. No. 10,660,987), which is a national stage application under 35U.S.C. § 371 of International Patent Application No. PCT/US2012/035696,filed on Apr. 28, 2012, which claims the benefit of and priority fromU.S. Provisional Patent Application No. 61/480,513, filed on Apr. 29,2011. The disclosures of each of the foregoing applications are herebyincorporated by reference herein in their entireties.

BACKGROUND

Cell encapsulation is a promising strategy for immunoisolating singlecells and cell clusters and thus preventing any immune response thatwould compromise the functionality of the cells upon implantation.Bio-encapsulation has been extensively employed for novel therapeutictrials in the fields of diabetes, hemophilia, cancer and renal failure.However, most trials have not been fully successful for a combination ofreasons:

-   -   lack of reproducibility in encapsulation and cell isolation        methods;    -   lack of suitable encapsulation materials which should be        biocompatible, mechanically and chemically stable, and have an        appropriate pore cut-off size to allow nutrient and by-product        flow in and out of the capsule while protecting encapsulated        biomaterial from immune system effects;    -   production of non-uniform or non-conformally coated capsules        (affecting oxygen and nutrient diffusion through the capsule and        therefore encapsulated cell viability);    -   inability to scale up the encapsulation process from small        animal studies to pre-clinical non-human primate studies; and    -   choices of unfavorable transplantation sites.        Such challenges to encapsulation technology may be seen in the        context of work in one of the most promising therapeutic fields        for cell encapsulation: diabetes.

Diabetes results from the autoimmune destruction of pancreatic betacells, one of the several cell types which make up the islets ofLangherans. Over the course of their lifetimes, diabetic patients mustfrequently monitor and control blood glucose levels and administerinsulin when they experience hyperglycemia, which has many collateraleffects. Islet allo-transplantation is a very promising therapy to treatdiabetic patients, but requires a lifetime of systemic immunosuppressionto avoid allograft rejection.¹

To avoid administration of immunosuppressive drugs at the systemiclevel, islet allografts can be immunoprotected by coating the cells fortransplantation with a polymeric capsule that allows diffusion ofoxygen, glucose and insulin while preventing cell-cell contact anddiffusion of cytotoxic molecules, which otherwise would trigger theimmune response against the graft and its ultimate rejection by thehost.² Islets have a non-uniform size that varies from about 50 to 300μm in diameter. Most coating procedures developed by others do not allowconformal coating of islets; capsule diameter is generally constant andindependent of islet size, and is thus normally larger than 300 μm toguarantee coating of larger islets.³ Because of the excess of cell-freecoating material, the total volume of the islet implant is greatlyincreased such that the only appropriately-sized grafting site is thepoorly-oxygenized abdominal cavity, which contributes to hypoxia of theencapsulated cells. Further, the thickness of the capsule increases thediffusion barrier to oxygen through the coating, also aggravating cellhypoxia, and delays glucose sensing and thus responsiveness of insulinsecretion' (FIG. 1A). Most of these encapsulation methods are based ongeneration of droplets of the coating material mixed with islets throughair-jet pump or electrostatic droplet generators.⁵

In contrast with encapsulation methods based on droplet generation,conformal coating of cell clusters of various diameters has been thefocus of some recent investigations. Most of these methods are based oneither (a) coating formation layer-by-layer directly onto cells (e.g.,by chemical reaction or photo-polymerization) or (b) a purelyhydrodynamic procedure, typically involving formation of particles bywater in oil emulsion formation or by break-up of a water jet in oil bythe fluid dynamic principle of Rayleigh-Plateau instability.^(3,10)Using these methods, it is possible to generate water particles with aconstant diameter uniquely dependent on the characteristics of the waterand the oil phase, the surface tension between the two phases and theratio of the hydrodynamic parameters of the two phases.^(6,7,8,9) In thefood and pharmaceutical industries, these methods have been extensivelyexploited to nano-encapsulate water-soluble drugs and other substances⁸and have only recently been extended to encapsulation of micron-sizesingle cells and cell clusters, with some reported success, as describedbelow.

Chabert M. and co-workers developed a microfluidic high-throughputsystem for encapsulating and self-sorting single cells based on theprinciple described above.¹⁰ However, their system is designed forencapsulation and sorting of single cells (40 μm in diameter or less),and cannot be applied to cell clusters because of the micro-dimensionsof their device, which would subject non-single cells to unaffordableshear stresses.

Garfinkel M. R. and co-workers developed another method to encapsulateislets by selectively withdrawing the islet-water phase from an externaloil phase to create a thin coating on cell clusters. In this method,water phase jetting in the oil phase is achieved by suction of the waterphase layer on top of the oil phase. In this design, turbulent flow iscreated in the water withdrawal area, ultimately leading to incompletecoating that necessitates a second round of encapsulation, increasingthe amount of stress to which the cells are subjected and reducing theyield of the process.¹¹ Further, the gel polymerization is achievedthrough photo-polymerization, which may compromise long-term function ofthe coated cells.

Hubbell J. A. and co-workers developed an approach of coating by achemical reaction directly on the cell surface, whereby aphotosensitizer was adsorbed to the surface of islets, and thephotosensitizer-treated islets were suspended in an aqueous solution ofa photopolymerizable macromer (U.S. Pat. No. 6,911,227).Photoillumination of the islet suspension led to the polymerization andcrosslinking of the macromer to create a conformal polymer gel bound tothe surface of the islets.

In view of the above, there remains a need in the art for efficient,high-yield methods of conformally coating cells and cell clusterswithout compromising cell functionality.

SUMMARY OF THE INVENTION

The present invention relates to a method for conformally coating cellsand cell clusters with hydrogels that are biocompatible, mechanicallyand chemically stable and porous, with an appropriate pore cut-off size.The methods of the invention are advantageously reproducible and resultin a relatively high yield of coated versus non-coated cell clusters,without compromising cell functionality. The invention further providesconformal coating devices configured to perform the methods of theinvention, methods of optimally utilizing said devices and purifying thecoated islets, and coated biomaterials made by said methods.

Other advantages of the present invention include (1) overall decreasein encapsulated biomaterial graft volume, (2) minimal diffusion barriersfor oxygen and nutrients through the capsules, (3) minimal delay ininsulin responsiveness to glucose challenge, (4) minimal damage to thecell/cell cluster surface, allowing cell renewal and reorganization and(5) easy scale up from the bench to the clinic.

To achieve these and other effects, we exploited the purely hydrodynamicprinciple of Chabert et al., as described above. Specifically, in theabsence of cells, a water phase is coaxially injected into an externaloil phase and flowed through a focusing region such that the internalwater phase can experience a transition from dripping to jetting withinthe oil phase and the water jet is elongated. The flow chamber thatcontains the two phases has a special focusing geometry that allows jetformation and acceleration (elongation) into a micrometer-size liquidjet. Jet dimension depends on the characteristics of the two phases andtheir fluid dynamic parameters. Surface tension between the water phaseand the oil phase then triggers a Rayleigh-Plateau instability betweenthe two phases that ultimately causes water jet break-up into microliterdroplets with a constant size that depends on (a) the geometry of thedevice, (b) the ratio between the water and oil flow rates, (c) theratio between the water and oil viscosities, and (d) the surface tensionbetween the two phases.

When cell clusters are added to the inner water phase, they flowcoaxially within the water jet (the water phase is flowing around thecluster since the system is axially symmetric). In the focusing regions,the elongation component of the flow allows for easy separation of thecell clusters. Once the jet breaks up, the cell clusters are coated witha thin water layer that is proportional to the size of the jet. Cellcluster-containing capsules thus have a diameter that is proportional tothe cluster size and the thickness of the capsule depends only on theexternal fluid dynamic conditions.

Since cluster diameter is bigger than jet diameter and the water flowrate is constant, even if the cell density of the water phase is high,the clusters are separated from each other by the elongation componentof the flow in the focusing region, which allows clusters to becomeindividually aligned in the center of the jet prior to encapsulation.This allows encapsulation of individual cell clusters within singledrops independent of cluster density.

There are several parameters which need to be controlled with thismethod in order to achieve conformal coating of biomaterials, such ascell clusters, with a precise thickness of coating: (1) water drippingto jetting transition, (2) jet break-up into microliter droplets (forcell cluster-free water phase) and into single cell cluster-containingdroplets (for cell clusters in water phase), (3) internal polymerizationof the coating material after jet break-up and before purification, and(4) efficient purification of coated cell clusters from the oil phaseand from biomaterial-free coating material.

Each of these issues has been addressed using computational models andby experimental optimization, as described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A, FIG. 1B, and FIG. 1C: FIG. 1A. Schematic showing results ofconformal coating by the methods of the invention (left) versusencapsulation by prior methods (right). The methods of the inventionallow for coating of cells and cell clusters such that the size of thecapsule is proportional to the size of the encapsulated cells/cellclusters. FIG. 1B. Schematic showing the procedure of conformal coating,in which the water phase containing the coating solution and the cellclusters is coaxially injected into an external oil phase and flowedthrough a focusing region such that the internal water phase canexperience a transition from dripping to jetting within the oil phaseand the water jet is elongated. Surface tension between the water phaseand the oil phase then triggers a Rayleigh-Plateau instability betweenthe two phases that ultimately causes water jet break-up into microliterdroplets with a constant size, resulting in the coating of cell clusterswith capsules that have a diameter proportional to cluster size. FIG.1C. Computational model showing 2D axisymmetric geometry used with:“more focusing” (top left), “less focusing” (top middle), and differentwater injection points (top right). The mesh has been created byimposing a maximum size of the element in the central axis (r=0) equalto 10⁻⁵ m (bottom).

FIG. 2A, FIG. 2B, FIG. 2C, FIG. 3A, FIG. 3B, FIG. 3C, FIG. 4A, FIG. 4B,FIG. 4C, FIG. 5A, FIG. 5B, FIG. 5C, FIG. 6A, FIG. 6B, FIG. 6C, FIG. 7A,FIG. 7B, FIG. 7C, FIG. 8A, FIG. 8B, FIG. 8C, FIG. 9A, FIG. 9B, FIG. 9C,FIG. 10A, FIG. 10B, FIG. 10C, FIG. 11A, FIG. 11B, and FIG. 11C:Computational models with parameters as specified in Table 1. Theoutputs of each simulation are: surface plot of the water phasedistribution within the oil phase at the last time point (FIG. 2A, FIG.3A, FIG. 4A, FIG. 5A, FIG. 6A, FIG. 7A, FIG. 8A, FIG. 9A, FIG. 10A, andFIG. 11A); surface plot of the velocity profiles at the last time point(FIG. 2B, FIG. 3B, FIG. 4B, FIG. 5B, FIG. 6B, FIG. 7B, FIG. 8B, FIG. 9B,FIG. 10B, and FIG. 11B); and boundary plot (z-axis, at r=0) of the totalstress in the r direction (Tr, FIG. 2C left, FIG. 3C left, FIG. 4C left,FIG. 5C left, FIG. 6C left, FIG. 7C left, FIG. 8C left, FIG. 9C left,FIG. 10C left, and FIG. 11C left) and the total stress in the zdirection (Tz, FIG. 2C right, FIG. 3C right, FIG. 4C right, FIG. 5Cright, FIG. 6C right, FIG. 7C right, FIG. 8C right, FIG. 9C right, FIG.10C right, and FIG. 11C right) vs. the position along the z-axis.

FIG. 2A, FIG. 2B, and FIG. 2C: Model 1.

FIG. 3A, FIG. 3B, and FIG. 3C: Model 2.

FIG. 4A, FIG. 4B, and FIG. 4C: Model 3.

FIG. 5A, FIG. 5B, and FIG. 5C: Model 4.

FIG. 6A, FIG. 6B, and FIG. 6C: Model 5.

FIG. 7A, FIG. 7B, and FIG. 7C: Model 6.

FIG. 8A, FIG. 8B, and FIG. 8C: Model 7.

FIG. 9A, FIG. 9B, and FIG. 9C: Model 8.

FIG. 10A, FIG. 10B, and FIG. 10C: Model 9.

FIG. 11A, 11B, and 11C: Model 10.

FIG. 12A and FIG. 12B: Flow chamber design characterized by a chamberwith a flow-focusing region (10 to 1 narrowing), a coaxial injectorsystem and a narrow coaxial outflow channel. FIG. 12A. Assembly of thedifferent parts and table with description of each part. FIG. 12B. Frontplane section view.

FIG. 13 : Schematic showing PEG functionalization with dVS (greater than90%) by Michael type addition of dVS in the presence of NaH.

FIG. 14 : Left: schematic showing the labelling of PEG-dVS withfluoresceinamine by Michael type addition in a sodium carbonate buffer(ibis). Right: fluorescent microscope image of FITC-PEG gel capsules.

FIG. 15A, FIG. 15B, FIG. 15C, and FIG. 15D: Confocal images of FITC-PEGcoated beads. Left: orthogonal projection of a z-scan of the entirecoated bead. Right: 3D reconstruction of the z-scan series, sectioned inthe midplane.

FIG. 16A, FIG. 16B, FIG. 16C, FIG. 16D, FIG. 16E, and FIG. 16F:Fluorescence microscope images of coated bead morphology, showingdifferent outcomes achieved by varying experimental conditions.FITC-PEG-dVS has been added to the water phase at 1% concentration tofluorescently label the coating. FIG. 16A. Low ratio of coated beads vs.empty polymer beads and big secondary beads. FIG. 16B. Low ratio ofcoated beads vs. empty polymer beads but smaller secondary beads. FIG.16C. Higher ratio of coated beads vs. empty polymer beads and smallersecondary beads but low encapsulation efficiency. FIGS. 16D-16F. Highratio of coated beads vs. empty polymer beads, small secondary beads andhigh encapsulation efficiency (optimized protocol).

FIG. 17A and FIG. 17B: Permeability and permselectivity of hydrogels forconformal coating. FIG. 17A. Permeability of different ALGINATE- andPEG-based hydrogels to 10 kDa FITC dextran as c/c_(inf) development overtime. FIG. 17B. Permselectivity of PEG ALG DTT to different molecularweight FITC dextran as c/c_(inf) development over time.

FIG. 18 : Biocompatibility of different ALGINATE and PEG-based hydrogelsin the subcutaneous site and under the kidney capsule at day 7.

FIG. 19A, FIG. 19B, and FIG. 19C: Conformal coating of rat islets ofLangerhans. FIG. 19A. Phase contrast microscopy of coated islets. FIG.19B. Confocal images of FITC-labeled PEG coatings. FIG. 19C. Confocalimages of 2000 kDa FITC dextran entrapped within PEG coatings. Blue:nuclear counterstain. Scale bars: 100 μm

FIG. 20A, FIG. 20B, and FIG. 20C: Functional response (insulin releaseupon glucose stimulation) of rat islets encapsulated with differenthydrogel compositions. FIG. 20A. PEG-dVS 8arm 10 kDa cross-linked withDTT: conformally coated islets at different percentages of PEG and MVGalginate (ALG) vs. islets within PEG clumps and rods. FIG. 20B. Isletsconformally coated with PEG-dVS 8arm 10 kDa cross-linked with DTT vs.linear HS-PEG-SH and vs. capping PEG-VS functional groups withbeta-mercaptoethanol. FIG. 20C. Islets conformally coated with PEG-dVS8arm 10 kDa cross-linked with DTT vs. multi-arm HS-PEG-SH vs. additionof MVG alginate (ALG). Low1: 60 mg/dL glucose, High: 300 mg/dL, Low2: 60mg/dL.

FIG. 21A, FIG. 21B, FIG. 21C, and FIG. 21D: Effect of timing betweenisolation/encapsulation/functional evaluation on islet viability andfunctional response (insulin release upon glucose stimulation) of ratislets encapsulated with 5% PEG-dVS 8arm 10 kDa 0.8% MVG cross-linkedwith DTT (PEG ALG). FIG. 21A. Live (green)/Dead (red) staining of ratislets encapsulated with PEG ALG two days after isolation and imagedright after encapsulation (left), 24 hours after encapsulation (middle)or 48 hours after encapsulation (right). FIG. 21B. Functional responseof naked islets 2, 3 or 4 days after isolation. FIG. 21C. Functionalresponse of islets encapsulated with PEG ALG one day after isolation andevaluated 24 and 48 hours after encapsulation. FIG. 21D. Functionalresponse of islets encapsulated with PEG ALG two days after isolationand evaluated 24 and 48 hours after encapsulation. L1: 60 mg/dL glucose,H: 300 mg/dL, L2: 60 mg/dL.

FIG. 22 : In vivo function of murine (C57BL/6) islets conformally coatedwith PEG ALG and transplanted under the kidney capsule of chemicallyinduced diabetic syngeneic mice, expressed as blood glucose of recipientmice over time. Nephrectomy was performed in order to confirm thatnormoglycemia was due to coated islets function.

FIG. 23 : Histological (H&E, left) and immunohistochemical (insulin:right) evaluation at rejection time of naked controls (top, day 11) andconformally coated (bottom, day 55) islets transplanted under the kidneycapsule of concordant xenogeneic recipients.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to methods and means for immunoisolatingbiomaterials, e.g., cells and cell clusters, to prevent immunerejection, inflammation, and/or autoimmune destruction while preservingcell functionality when the biomaterials are implanted into a subject.

In some embodiments, the invention provides a method for conformallycoating a biomaterial with a coating material, comprising the steps of:

-   -   a) injecting a water phase within a coaxial oil phase in a        coating device that allows for a transition from dripping to        jetting and flow elongation of the water phase within the oil        phase;    -   b) adding the biomaterial and the coating material to the water        phase, wherein polymerization of the coating material occurs        downstream of the jet breakup of the water phase into particles,        resulting in the conformal coating of the biomaterial with the        coating material; and    -   c) collecting the outflow of the coating device; and optionally,        further comprising the step or steps of:    -   d) purifying the conformally coated biomaterial and        biomaterial-free coating material from the oil phase; and    -   e) separating the conformally coated biomaterial from the        biomaterial-free coating material.

See, e.g., FIG. 1B.

The methods of the invention may be used to encapsulate any materialthat may benefit from immunoisolation when implanted into a subject. Thematerial may be non-uniform. In one embodiment, the material that maybenefit from immunoisolation is a biomaterial. In some embodiments, themethods of the invention are used to encapsulate one or more of cells,cell clusters, subcellular organelles, biologics such as proteins,nucleic acids and antibodies, and non-biologics (e.g., small molecules)such as drugs. In some embodiments, the methods of the invention areused to encapsulate cells and/or cell clusters. In a particularembodiment, the methods of the invention are used to encapsulatepancreatic islet cells and cell clusters.

In certain embodiments, the conformally coated cells and cell clustersmay comprise one or more of autologous, heterologous, syngeneic,allogeneic, or xenogeneic pancreatic islets, alone or in combinationwith other cell types (e.g., Sertoli cells, mesenchymal and bone marrowderived cells, endothelial progenitor cells, stem cells, regulatory Tcells T_(reg), etc., each referred to generically as implant “helpercells”) that provide growth factors and/or other beneficial agents forestablishment, maintenance or expansion of the conformally coated cells,or otherwise to help the conformally coated cells deliver a therapeuticeffect when implanted in a host. In one embodiment, the helper cells aremesenchymal stem cells.

As used herein, the term “host” refers to the recipient of implantedbiomaterial and includes all animals. In one embodiment, the host is amammal. In an exemplary embodiment, the host is human.

The methods of the invention may be used advantageously for conformalcoating in cell therapy model systems. The conformally coated cells maydeliver a therapeutic benefit, e.g., by expressing a therapeutic factorin vivo upon implantation. Examples of such cells include, but are notlimited to, cells that produce: insulin to treat diabetes; dopamine totreat Parkinson's disease (Minquez-Castellanos et al., J NeurolNeurosurg Psychiatry in press (2007)); growth hormone to treat dwarfism(Chang et al., Trends Biotechnol 17:78-83 (1999)); factor VIII andfactor IX (Chang et al., Trends Biotechnol 17, 78-83 (1999)) to treathemophilia; and erythropoietin to treat anemia (Rinsch et al., KidneyIntern 62:1395-1401 (2002)). Many more beneficial cell produced factorsor cellular/tissue activities may be imagined. In some embodiments, theconformally coated cells may express and/or deliver more than onetherapeutic factor, or may comprise two or more cell types deliveringone or more therapeutic factors. In some embodiments, the conformallycoated cells also or alternatively express and/or deliver an antagonist,agonist, analog, derivative, chimera, fusion, or fragment of atherapeutic factor to deliver a therapeutic effect when implanted in ahost.

In some embodiments, at least some of the conformally coated cells alsoor alternatively deliver a therapeutic effect without secreting adiffusible factor. In certain embodiments, the conformally coated cellsprovide an enzymatic activity that, for example, converts a substrateinto a product having a beneficial effect, and/or metabolizes,sequesters, or absorbs a detrimental substance. In certain embodiments,the conformally coated cells deliver a therapeutic effect through abiological material-linked factor, such as a cell surface-linked factor.

In some embodiments, the conformally coated cells naturally deliver atherapeutic effect, without genetic modifications, upon implantationinto a host. In some embodiments, the conformally coated cells aregenetically engineered to deliver a therapeutic effect. As non-limitingexamples, the cells may be transfected with expression vectors, ortransduced with lentiviral vectors, that make the cells capable ofexpressing one or more therapeutic and/or helper cell factors. Inanother embodiment, the cells may comprise, consist of, or consistessentially of cells transfected with expression vectors that make thecells capable of expressing one or more therapeutic and/or helper cellfactors. Such expression may be in a constitutive or in a regulatedmanner, e.g., in response to biological modulators in the bloodstream ortissues to which the cells are exposed.

In some embodiments, the cells for conformal coating are derived fromcadaver tissue or from living tissue. In some embodiments, the cells areof non-mammalian or mammalian origin, non-human origin or human origin,self or non-self. The cells may be pluripotent, multipotent, totipotent,or differentiated embryonic or adult stem cells; primary differentiatedcells; or immortalized cells, among other cell types. In certainembodiments, stem cells comprise, e.g., cells derived from cord blood,amniotic fluid, menstrual blood, placenta, Wharton's jelly,cytotropoblasts, and the like. The cells may also comprise anycombination of the above-listed cell types.

Exemplary therapeutic factors which may be delivered by the conformallycoated cells include, but are not limited to, one or more of: insulin,glucagon, erythropoietin; Factor VIII; Factor IX; hemoglobin; albumin;neurotransmitters such as dopamine, gamma-aminobutyric acid (GABA),glutamic acid, serotonin, norepinephrine, epinephrine, andacetylcholine; growth factors such as nerve growth factor (NGF),brain-derived neurotrophic factor (BDNF), neurotrophin-3 (NT-3),neurotrophin 4/5 (NT-4/5), ciliary neurotrophic factor (CNTF), glialcell line-derived neurotrophic factor (GDNF), cholinergicdifferentiation factor/leukemia inhibitory factor (CDF/LIF), epidermalgrowth factor (EGF), insulin-like growth factor (IGF), fibroblast growthfactor (FGF), and platelet-derived growth factor (PDGF); pain inhibitorssuch as Substance P, catecholamines, dynorphins, endorphins, orenkephalins; hormones such as parathyroid hormone or growth hormone;immunomodulators such as granulocyte-macrophage colony stimulatingfactor (GM-CSF); neuromodulators; lymphokines; cytokines; cofactors;antibodies; aptamers; and enzymes. Choice of one or more therapeuticfactors and the concentrations at which they are produced and releasedfrom the cells are dictated by the needs of the patient being treated,and may be readily determined empirically by the skilled practitioner.

In some embodiments, the conformally coated cells produce a therapeuticfactor that has insulin-like or insulin-regulatory activity. In certainembodiments, the therapeutic factor is insulin. In certain embodiments,the therapeutic factor is a precursor form of insulin, such aspreproinsulin or proinsulin. In certain embodiments, the therapeuticfactor is an insulin chimeric or fusion protein.

In some embodiments, the therapeutic effect provided by the conformallycoated cells comprises regulation of insulin levels in the blood. Incertain embodiments, the therapeutic effect comprises regulation ofglucose levels in the blood. In other embodiments, the therapeuticeffect comprises regulation of levels of one or more other biologicalresponse regulators in the blood of the patient.

In some embodiments, the therapeutic factor(s) are released from theconformally coated cells due to the receipt of a stimulus or signal. Forimplanted cells, the stimulus or signal may be received from the host(e.g., changes in blood levels of glucose, hormones, metabolic signalingagents, chemical signaling molecules, etc.).

In some embodiments, the cells and/or cell clusters of the invention aregenerally uniform in size. In other embodiments, the cells and/or cellclusters of the invention are not uniform in size. In certainembodiments, the cells and/or cell clusters vary from 10 μm to 10000 μmin diameter; from 25 μm to 500 μm in diameter; or from 40 μm to 400 μmin diameter. In a particular embodiment, the cells and/or cell clustersvary from 50 to 300 μm in diameter. In some embodiments, the cellsand/or cell clusters that vary from 50 to 300 μm in diameter compriseislet cells.

The coating material used in the conformal coating methods of theinvention is biocompatible and is mechanically and chemically stable.Further, materials preferred for conformal coating do not interfere, ordo not interfere substantially, with the function of the encapsulatedbiomaterial, and reduce, minimize or eliminate an immune response whenthe encapsulated biomaterial is implanted in a host. In certainembodiments, the coating material can be polymerized by internalgelation. In certain embodiments, the material used in the conformalcoating methods of the invention is biodegradable.

In some embodiments, the coating material comprises one or more ofpolyethylene glycol (PEG), polyethylene oxide (PEO), poly(N-vinylpyrrolidinone) (PVP), polyethyl oxazoline, polyvinyl alcohol (PVA),polythyloxazoline (PEOX), poly(amino acids), and Biodritin®;polysaccharides such as alginate, hyaluronic acid, chondroitin sulfate,dextran, dextran sulfate, heparin, heparin sulfate, heparan sulfate,chitosan, gellan gum, xantham gum, guar gum, water soluble cellulosederivatives and carrageenan; and proteins such as gelatin, collagen andalbumin. In certain embodiments, the coating material is polyethyleneglycol (PEG).

In certain embodiments, the coating material is mono-armed. In certainembodiments, the coating material is multi-armed.

In some embodiments, the conformal coating has permeabilitycharacteristics that allow for exchange of nutrients and cellularby-products and release of therapeutic factors, but that may alsopreclude host immune effector molecules and/or other undesired elementsfrom entering the capsules. In certain embodiments, the conformalcoating comprises pores with a cut-off size of 100, 110, 120, 130, 140,145, 150, 155, 160, 170, 180, 190, 200, 210, 220, 230, 240 or 250 kDa.In certain embodiments, the conformal coating comprises pores with acut-off size of 150 kDa. In certain embodiments, the conformal coatingcomprises pores with a cut-off size of up to 500 kDa.

The thickness of the conformal coating does not depend on thesize/diameter of the coated material. In some embodiments, the thicknessof the coating ranges from 1 μm to 100 μm, from 5 μm to 50 μm, or from 8μm to 25 μm. In some embodiments, the thickness of the coating rangesfrom 25-50 μm. In some embodiments, the thickness of the coating rangesfrom 10-20 μm.

In some embodiments, the coating is visualized by labeling the coatingmaterial with a detectable marker. The marker may be, e.g., afluorescent, enzymatic, chemiluminescent, or epitopic label. In certainembodiments, the coating may be visualized by entrapping high molecularweight FITC dextran within the coating material. In a particularembodiment, the labeled coating material is PEG-dVS-FITC.

In some embodiments, the coating material may be chemically altered tocontain functional groups. In some embodiments, the functional groupshelp stabilize the coating. Further, the coating material may comprisetherapeutic factors or other molecules that associate with suchtherapeutic factors, such as receptors or affinity agents (see, e.g.,Kim et al., Biomacromolecules 4(5):1214-1223 (2003)). Therapeuticfactors may be incorporated into the coating material via covalentcross-linking, emulsification, ionic interactions, specific affinityinterations, simple entrapment, or any combination thereof.

In one embodiment, the coating material comprises anti-inflammatorymolecules to reduce the host inflammatory response upon implantation ofthe conformally coated cells. Exemplary anti-inflammatory agents includecorticosteroids (dexamethasone, cortisol, prednisolone, loteprednoletabonate, flucinolone acetonide, and others), interleukin-1 (IL-1),interleukin-10 (IL-10), alpha 1-antitrypsin (AAT), lisofylline,pentoxyfilline, COX-2 inhibitors, interleukin-1 receptor antagonistpeptide (IRAP), interleukin-10 (IL-10), alpha 1-antitrypsin (AAT),TGF-beta; antibodies to IL-1, interferon-gamma, and TNF-alpha;anti-tissue factor, and complement inhibitors. In some embodiments, thecoating material comprises extracellular matrix (ECM) molecules such ascollagen type I or IV, laminin, fibronectin, orarginine-glycine-aspartate peptides (Beck et al., Tissue Eng 13 (3):1-11 (2007)). In some embodiments, the anti-inflammatory and/or ECMmolecules are tethered to the surface of the coating material. Incertain embodiments, the molecules are coated or encapsulated for slowrelease.

Conformal coating of the biomaterial takes place in a coating device. Asused herein, the term “coating device” refers to any device that iscapable of conformally coating a biomaterial. In some embodiments, thecoating device is a device that allows for a transition from dripping tojetting and elongation of a water phase within a non-miscible (e.g.,oil) phase, wherein the water phase undergoes jet breakup intoparticles. In some embodiments, the coating device is a flow chambercomprising one or more oil phase inlets, one or more water phase inlets(which may be the same as or different from the oil phase inlets), andone or more flow focusing regions downstream of the inlets whereco-flowing jets of the oil phase focus the water phase. The flow chambermay further comprise one or more channels downstream of the flowfocusing region(s). The diameter of the water phase channel(s) may be,e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7,1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2,3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm in diameter. The diameter ofthe oil phase channel(s) may be, e.g., 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5,9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16,16.5, 17, 17.5, 18, 18.5, 19, 19.5, or 20 mm in diameter. In certainembodiments, the diameter of the oil phase channel(s) may be up to 100mm. The length of the channel(s) may be, e.g., 5, 6, 7, 8, 9, 10, 11,12, 13, 14 or 15 mm. The channels may lead to one or more outlets fromthe flow chamber. See, e.g., FIGS. 12A and 12B for examples of detailsin designing and fabricating the flow chamber.

In some embodiments, the device provides flow focusing from a channel of10d to a channel of d ( 1/10 restriction in diameter to allow transitionfrom dripping to jetting). In certain embodiments, d ranges from 0.5-10mm. In certain embodiments, d ranges from 1-4 mm. In a particularembodiment, d is around 1 mm. In some embodiments, the focusing angle ofthe device ranges from 100 to 5 degrees (more to less focusing). Incertain embodiments, the focusing angle ranges from 90 to 10 degrees. Incertain embodiments, the focusing angle is greater than 10, 20, 30, 40,50, 55, 60, 65, 70, 80, or 90 degrees. In certain embodiments, thefocusing angle of the device is about 60 degrees. In some embodiments,the flow focusing region is 50, 60, 70, 80, 90, 100, 110, 120, 130, 140,or 150 mm long. In certain embodiments, the flow focusing region is 100mm long.

In some embodiments, the diameter of the external oil phase chamber(cylinder) is 1-20 mm. In some embodiments, the diameter of the externaloil phase chamber is 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 mm. In aparticular embodiment, the diameter of the external oil phase chamber is10 mm. In some embodiments, the external oil phase chamber is fed by alateral port 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm upstream (cylinderaxial distance) of the coaxial injection port for the water phase. Incertain embodiments, the lateral port is 5 mm upstream of the waterphase injection port. In certain embodiments, the external oil phasechamber is fed by more than one lateral port 1, 2, 3, 4, 5, 6, 7, 8, 9,or 10 mm upstream (cylinder axial distance) of the coaxial injectionport for the water phase.

In some embodiments, the tip of the water injection needle co-localizeswith the base of the focusing region of the device. In some embodiments,the tip of the water injection needle is positioned about 0, 0.1, 0.2,0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 2, 3, 4, or 5 mm upstream ordownstream (cylinder axial distance) of the base of the focusing regionof the device. In a particular embodiment, the tip of the waterinjection needle is positioned about 0.5 mm upstream of the focusingregion.

In a particular embodiment, the device is characterized by an externaloil phase chamber 10 mm in diameter, fed by a lateral port 5 mm upstreamof the coaxial injection port for the water phase, which is 0.5 mmupstream of the flow focusing region, and flow focusing occurs in achannel that constricts from 10 mm to 1 mm in diameter and is 100 mm inlength, with a focusing angle of 60 degrees.

In some embodiments, the device is able to coat cells and/or cellclusters of greater than 40, 50, 60, 70, 80, 90, 100, 150, 200, 250,300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or1000 μm in diameter. In certain embodiments, the device is able to coatcells and/or cell clusters of greater than 40 μm in diameter. In someembodiments, the device is able to coat cells and/or cell clusters of upto 1000 μm in diameter.

In some embodiments, the water phase flow, the oil phase flow, or both,are maintained by a peristaltic pump. In some embodiments, the waterphase flow, the oil phase flow, or both, are maintained by a syringepump. In one embodiment, the water phase flow is maintained by a syringepump and the oil phase flow is maintained by a peristaltic pump.

In some embodiments, the conformal coating methods of the invention donot involve: (1) generation of droplets of the coating material mixedwith islets through air-jet pump or electrostatic droplet generators;(2) coating formation layer by layer directly on the cells (3) coatingby a chemical reaction directly on the cell surface; and/or (3)photopolymerization.

In some embodiments in which cells and/or cell clusters are thebiomaterial to be conformally coated, the concentration of cells/cellclusters added to the water phase may range from 100-1,000,000 cells/ml,500-750,000 cells/ml, 1,000-500,000 cells/ml, or 2,500-250,000 cells/ml.In certain embodiments, the concentration of cells/cell clusters addedto the water phase ranges from 5,000 to 100,000 cells/ml. In aparticular embodiment, the 5,000 to 200,000 cells/ml added to the waterphase are pancreatic islet cells, which may optionally be enriched forinsulin secreting beta cells or cell clusters.

The water phase may comprise a surfactant. In some embodiments, thesurfactant comprises one or more of, e.g., Pluronic (F-68 and/or F-127)and PEG-PPS block co-polymers. In one embodiment, the surfactant isPluronic F-68. In some embodiments, the surfactant concentration in thewater phase ranges from 0-10%, 0-8%, 0-6%, 0-5%, 0-4%, 0-3%, 0-2.5%,0-2%, 0-1.5%, or 0-1%. In certain embodiments, the surfactantconcentration ranges from 0 to 5%. In one embodiment, the surfactantconcentration is 2%. In another embodiment, the surfactant concentrationis 1%.

The water phase may comprise an agent to coat the surface of the isletand prevent clumping. In some embodiments, the agent comprises mediumviscosity G-groups alginate (MVG). In certain embodiments, the agentcomprises sodium alginate with 60% guluronate (G) and 200000-300000g/mol viscosity (PRONOVA UP MVG, Product#4200106, NovaMatrix, Sandvika,Norway). In other embodiments, the agent additionally or alternativelycomprises a charged synthetic or natural polymeric (e.g., polyacrylicacid) or non-polymeric (e.g., heparin) compound.

In some embodiments, the pH of the water phase is 1, 1.5, 2, 2.5, 3,3.5, 4, 4.5, 5, 5.5, 6, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7,7.5, or 8. In particular embodiments, the pH of the water phase is 4.5,5.5, 6.5, or 7. In one embodiment, the pH of the water phase is 6-7.

In certain embodiments, the water phase comprises cells/cell clusters inmedia, surfactant, and one or more thiolating or reducing reagents(which may be, e.g., mono- or multi-functional agents that are linear ormulti-armed). In some embodiments, the cells/cell clusters compriseislet cells, the media is serum-free or is Hanks' Balanced Salt Solution(HBSS), the surfactant is Pluronic-F68, and/or the thiolating orreducing reagent is DTT. In some embodiments, the water phase comprises5-10% PEG (e.g., 5% or 10% PEG), 0-0.8% medium viscosity G-groupsalginate (e.g., 0, 0.4% or 0.8% MVG), 0-2% Pluronic-F68 (e.g., 0%, 1% or2% Pluronic-F-68, 50,000-100,000 islet cells/ml (e.g., 50,000 or 75,000islet cells/ml), and 0.31-0.62% w/v DTT (e.g., 0.31% or 0.62% w/v DTT)in serum-free media or HBSS without Ca²⁺ and Mg²⁺ at pH 4.5-7.4 (e.g.,pH 4.5, 5, 5.5, 6, 6.5, 7 or 7.4); and the oil phase comprises 0-0.2%triethanolamine (e.g., 0%, 0.02% or 0.2% triethanolamine). The conformalcoating methods of the invention encompass any combinations of thesevalues. In certain embodiments, for example, the water phase comprises5-10% PEG, 2% Pluronic-F68, 75,000 islet cells/ml, and 0.31-0.62% w/vDTT in serum-free media at pH 6.5. In other embodiments, the water phasecomprises 5-10% PEG, 75,000 islet cells/ml, and 0.31-0.62% w/v DTT inHBSS without Ca²⁺ and Mg²⁺ at pH 4.5 or 5. In other embodiments, thewater phase comprises 5% or 10% PEG, 0.8% medium viscosity G-groupsalginate, 2% Pluronic-F68, 50,000 islet cells/ml, and 0.31 or 0.62% w/vDTT in calcium and magnesium free HBSS at pH 7. In other embodiments,the water phase comprises 5% or 10% PEG, 0.8% medium viscosity G-groupsalginate, 75,000 islet cells/ml, and 0.31 or 0.62% w/v DTT in calciumand magnesium free HBSS at pH 6. In one embodiment, the inventionprovides a method wherein the water phase comprises 10% PEG, 2%Pluronic-F68, 75,000 islet cells/ml and 0.62% w/v DTT in serum-freemedia at pH 6.5; wherein the oil phase comprises PPG with 10% Span80,wherein said oil phase optionally further comprises 0.02%triethanolamine (TEA). In another particular embodiment, the inventionprovides a method wherein the water phase comprises 5% PEG, 1%Pluronic-F68, 75,000 islet cells/ml and 0.31% w/v DTT in HBSS withoutCa²⁺ and Mg²⁺ at pH 4-6; wherein the oil phase comprises PPG with 10%Span80, wherein said oil phase optionally further comprises 0.02%triethanolamine. In another particular embodiment, the inventionprovides a method wherein the water phase comprises 5% PEG, 1%Pluronic-F68, 0.8% medium viscosity G-groups alginate, 75,000 isletcells/ml and 0.31% w/v DTT in HBSS without Ca²⁺ and Mg²⁺ at pH 7;wherein the oil phase comprises PPG with 10% Span80, wherein said oilphase optionally further comprises 0.02% triethanolamine. In anotherparticular embodiment, the invention provides a method wherein the waterphase comprises 5% PEG, 0.8% medium viscosity G-groups alginate, 75,000islet cells/ml and 0.31% w/v DTT in HBSS without Ca²⁺ and Mg²⁺ at pH 6;wherein the oil phase comprises PPG with 10% Span80, wherein said oilphase optionally further comprises 0.02% triethanolamine. In anotherparticular embodiment, the invention provides a method wherein the waterphase comprises 5% PEG, 0.8% medium viscosity G-groups alginate, 75,000islet cells/ml and 0.31% w/v DTT in HBSS without Ca²⁺ and Mg²⁺ at pH 5;wherein the oil phase comprises PPG with 10% Span80, wherein said oilphase optionally further comprises 0.02% triethanolamine. In any of theembodiments described herein, the oil phase may optionally comprise,e.g., 0.01%-0.5% triethanolamine, e.g., 0.02%-0.2% ethanolamine. In someembodiments, the oil phase may optionally comprise 0.2% triethanolamine,e.g., instead of 0.02% triethanolamine.

In certain embodiments, the oil phase comprises one or more of, e.g.,polypropylene glycol (PPG) or mineral oil with a viscosity of at least2.5 times more than the viscosity of the water phase. The oil phase mayfurther comprise one or more agents selected from, e.g., Span80 and/ortriethanolamine.

In some embodiments, the oil phase comprises PPG. In certainembodiments, the oil phase comprises PPG with 1-20%, 5-15%, 6-14%,7-13%, 8-12%, 9-11%, or 10% Span80, and/or 0-2%, 0.005-0. 5%,0.008-0.05%, or 0.01-0.02% triethanolamine. In a particular embodiment,the oil phase comprises PPG with 10% Span80. In some embodiments, theoil phase comprising PPG with 10% Span80 further comprises 0.01%, 0.02%,or 0.2% triethanolamine (TEA).

In some embodiments, the flow rates of the water phase (Qw) and the oilphase (Qo) are respectively selected from: 10 μl/min and 3.5 ml/min; 1μl/min and 3.5 ml/min; 10 μl/min and 7 ml/min; 50 μl/min and 0.5 ml/min;50 μl/min and 2.5 ml/min; 150 μl/min and 0.5 ml/min; and 150 μl/min and2.5 ml/min. In some embodiments, air is injected before the water phaseto allow stabilization of the water in the oil jet. In certainembodiments, air is drawn into an injection catheter containing thewater phase, such that the bubble of air can be injected into the oilphase prior to injection of the water phase into the oil phase to helpvisualize the beginning of the water phase.

The flow rates of the water phase and the oil phase may be adjusted overtime. In some embodiments, the water phase is reduced over time whilethe oil phase is increased. In a particular embodiment, the water phaseenters the oil phase first at 50 μl/min and is then reduced to 10μl/min. In certain embodiments, the oil phase rate is graduallyincreased from 0.5 to 3.5 ml/min while the water phase is decreased andis then kept constant for the entire encapsulation process, or the oilphase rate is kept constant at 3.5 ml/min throughout the encapsulationprocess.

In some embodiments, the ratio of the oil phase velocity to the waterphase velocity is between 70 and 500. In certain embodiments, the ratiois 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 310, 320, 330, 340, 350,360, 370, 380, 390, 400, 450, or 500. In a particular embodiment, theratio is 350.

In some embodiments, the ratio of the oil phase viscosity to the waterphase viscosity is between 2.5 and 100. In certain embodiments, theratio is 2.5, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 5, 10,20, 30, 40, 50, 60, 70, 80, 90, or 100. In a particular embodiment, theratio is 3.5.

Upon breakup of the water jet, the material for encapsulation (e.g.,cells and/or cell clusters) is coated with a thin, coatingmaterial-containing water layer that is proportional to the size of thejet, allowing for conformal coating. The coated cells/cell clusters arethen collected from the outflow of the coating device. In someembodiments, after collection, the coated cells and/or cell clusters arekept under stirring for, e.g., 1-30, 5-20, or 8-12 minutes to avoidcoalescence until polymerization of the coating is completed. In someembodiments, the stirring takes place at between 4 and 25° C. Inparticular embodiments, the stirring takes place at 25° C. In someembodiments, the stirring speed is between 50-500 rpm or 100-300 rpm. Inone embodiment, the coated cells and/or cell clusters are kept stirringfor about 10 minutes. In another embodiment, the coated cells and/orcell clusters are collected in a vessel and allowed to settle bygravity. In some embodiments, the coated cells and/or cell clusters arekept without stirring in the outer bath for, e.g., 1-30, 5-20, or 8-12minutes to allow polymerization of the coating to complete. In someembodiments, the coated cells and/or cell clusters are collected withina vessel comprising PPG and 10% Span80 and 0.02% TEA. In otherembodiments, the coated cells and/or cell clusters are collected withina vessel comprising PPG and 10% Span80 and 0.2% TEA. In otherembodiments, the coated cells and/or cell clusters are collected withina vessel comprising PPG and 0.02 or 0.2% TEA.

The oil phase may then be separated from the water phase. In someembodiments, the separation occurs through centrifugation and/or hexaneextraction. In certain embodiments, said centrifugation comprises thesteps of:

-   -   a) centrifuging the outflow to separate the conformally coated        biomaterial and biomaterial-free coating material from the oil        phase; and    -   b) removing the oil phase supernatant from the conformally        coated biomaterial and biomaterial-free coating material.        In certain embodiments, the oil phase is separated from the        water phase by centrifugation for 5-20 minutes at 1000-2000 rpm        followed by 1-10 minutes at 100-1000 g. In a particular        embodiment, the oil phase is separated from the water phase by        centrifugation for 5 minutes at 1500 rpm followed by 1 minute at        500 g.

In some embodiments, the hexane extraction comprises the steps of:

-   -   a) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising        hexane;    -   b) centrifuging the mixture of step a) to separate the        conformally coated biomaterial and biomaterial-free coating        material from the hexane; and    -   c) removing the hexane supernatant.

In some embodiments, the hexane extraction further or alternativelycomprises the steps of:

-   -   d) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising        hexane and a buffer;    -   e) centrifuging the mixture of step d) to separate the        conformally coated biomaterial and biomaterial-free coating        material from the hexane and buffer; and    -   f) removing the hexane/buffer supernatant.        The conformally coated biomaterial and biomaterial-free coating        material may then be resuspended in an aqueous solution, e.g.,        in buffer.

In other embodiments, the hexane extraction further or alternativelycomprises the steps of:

-   -   d) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising or        consisting of hexane;    -   e) adding the buffer to the hexane composition and mixing, e.g.,        by inverting the vessel;    -   f) centrifuging the mixture of step e) to separate the        conformally coated biomaterial and biomaterial-free coating        material from the hexane composition and buffer; and    -   g) removing the hexane/buffer supernatant.        In some embodiments, a second extraction with hexane may be        performed.

In a particular embodiment, the hexane extraction comprises the stepsof:

-   -   a) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising        hexane;    -   b) adding buffer (HBSS without Ca²⁺ and Mg²⁺) to the coated        biomaterial and biomaterial-free coating material and hexane mix        and mixing, e.g., by inverting the vessel    -   c) centrifuging the mixture of step b) for 5 min at 500 g;    -   d) removing the hexane and buffer supernatant, adding buffer        (HBSS without Ca²⁺ and Mg²⁺) and resuspending the conformally        coated biomaterial and biomaterial-free coating material;    -   e) centrifuging the mixture of step d) for 30 sec at 500 g;    -   f) removing the buffer supernatant, adding hexane and        resuspending the conformally coated biomaterial and        biomaterial-free coating material; adding buffer (HBSS without        Ca²⁺ and Mg²⁺) and resuspending the material;    -   g) centrifuging the mixture of step f) for 30 sec at 500 g; and    -   h) removing the hexane/PBS supernatant.        The conformally coated biomaterial and biomaterial-free coating        material may then be resuspended in PBS.

It may be desirable to separate the coated cells and/or cell clustersfrom biomaterial-free coating material. This separation may be achievedby any of a number of size or density based separation techniques wellknown in the art, e.g., by gradient centrifugation. In certainembodiments, coated cells and/or cell clusters are further purified fromcoating material by gradient centrifugation, comprising the steps of:

-   -   a) layering solutions to form a density gradient capable of        separating the conformally coated biomaterial and the        biomaterial-free coating material;    -   b) applying the conformally coated biomaterial and        biomaterial-free coating material to the density gradient;    -   c) centrifuging the density gradient to separate the conformally        coated biomaterial from the biomaterial-free coating material;        and    -   d) removing the part of the gradient containing the        biomaterial-free coating material.        In one embodiment, the solutions layered to form the gradient        are at the densities of (1) 1-1.1 g/ml, e.g., 1.042 g/ml,        and (2) media. In some embodiments, more than 50, 60, 70, 80,        85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100% of the        coated biomaterial is purified from the biomaterial-free coating        material. In a certain embodiment, more than 95% of the coated        biomaterial is purified from the biomaterial-free coating        material.

In a particular embodiment, the invention provides a method wherein thewater phase comprises 10% PEG, 2% Pluronic-F68, and 0.62% w/v DTT inserum-free media at pH 6.5;

wherein the oil phase comprises PPG with 10% Span80, wherein said oilphase optionally comprises 0.02% triethanolamine. In another particularembodiment, the invention provides a method wherein the water phasecomprises 5% PEG, 1% Pluronic-F68, and 0.31% w/v DTT in HBSS at pH 5.5;wherein the oil phase comprises PPG with 10% Span80, wherein said oilphase optionally comprises 0.02% triethanolamine. In another particularembodiment, the invention provides a method wherein the water phasecomprises 5% PEG, 1% Pluronic-F68, 0.8% medium viscosity G-groupsalginate and 0.31% w/v DTT in HBSS at pH 7; wherein the oil phasecomprises PPG with 10% Span80, wherein said oil phase optionallycomprises 0.02% triethanolamine. In another particular embodiment, theinvention provides a method wherein the water phase comprises 5% PEG,0.8% medium viscosity G-groups alginate and 0.31% w/v DTT in HBSS at pH4-7; wherein the oil phase comprises PPG with 10% Span80, wherein saidoil phase optionally comprises 0.02-2% triethanolamine (e.g., 0.02% or0.2% triethanolamine). In any of these embodiments, the coating devicemay comprise a flow chamber comprising a “more focusing” flow focusingregion with constriction of channel inner diameter from 10 mm to 1 mmwith a focusing angle of 60 degrees, and a channel downstream of theflow focusing region that is about 1 mm in diameter and 100 mm inlength;wherein the method comprises the steps of:

-   -   a) applying the oil phase to the flow chamber;    -   b) injecting air into the flow chamber through a needle whose        tip is localized 0.5 mm upstream of the base of the focusing        region;    -   c) injecting the water phase into the flow chamber through said        needle, wherein the water phase is first injected at 50 μl/min        and then reduced to 10 μl/min, while the oil phase is maintained        at 3.5 ml/min, such that the surface tension between the water        and the oil phase causes the water jet to break up into        microliter sized droplets comprising the conformally coated        biomaterial and biomaterial-free coating material;    -   d) collecting the outflow from the flow chamber;    -   e) centrifuging the outflow to separate the conformally coated        biomaterial and biomaterial-free coating material from the oil        phase;    -   f) removing the oil phase supernatant from the conformally        coated biomaterial and biomaterial-free coating material;    -   g) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising        hexane, and adding buffer and mixing (e.g., by inverting the        vessel);    -   h) centrifuging the mixture of step g) to separate the        conformally coated biomaterial and biomaterial-free coating        material from the hexane and buffer;    -   i) removing the hexane/buffer supernatant;    -   j) resuspending the conformally coated biomaterial and        biomaterial-free coating material in a composition comprising a        buffer;    -   k) centrifuging the mixture of step j) to separate the        conformally coated biomaterial and biomaterial-free coating        material from the buffer;    -   l) removing the buffer supernatant;    -   m) optionally repeating steps g)-j);    -   n) layering solutions to form a density gradient capable of        separating the conformally coated biomaterial and the        biomaterial-free coating material;    -   o) applying the conformally coated biomaterial and        biomaterial-free coating material to the density gradient;    -   p) centrifuging the density gradient to separate the conformally        coated biomaterial from the biomaterial-free coating material;        and    -   q) removing the part of the gradient containing the        biomaterial-free coating material.        In certain embodiments, the islet cells and/or the PEG are added        to the water phase before injecting it into the flow chamber, or        alternatively, after injecting it into the flow chamber.

If the coating material bears a fluorescent label, the conformallycoated cells and/or cell clusters can be visualized by, e.g.,fluorescence microscopy, fluorocytometry, flow cytometric cell sortingtechnology, or by a fluorescent plate reader. In some embodiments, thefluorescently-labeled conformally coated cells can be detected and/orisolated using, e.g., flow cytometry or FACS.

In some embodiments, the methods of the invention are scaled up toconformally coat at least 50,000; 100,000; 150,000; 200,000; 300,000;400,000; 500,000; 600,000; 700,000; 800,000; 900,000; or 1,000,000 cellsand/or cell clusters at the same time. In some embodiments, this scaleup is achieved by performing the methods of the invention in a series ofchambers. In one embodiment, the methods of the invention are scaled upby assembling a series of parallel vertical chambers in, e.g., a radialconfiguration in which radial flow to each chamber feeds the water phaseto each separate chamber with comparable hydrodynamic flowcharacteristics. In some embodiments, the coated cells and/or cellclusters and biomaterial-free coating material from each chamber arecollected in separate containers. In some embodiments, the coated cellsand/or cell clusters and biomaterial-free coating material from eachchamber are collected in the same container and purified at the sametime.

In some embodiments, the methods of the invention provide conformalcoating of greater than 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70,75, 80, 85, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100% of thebiomaterial introduced into the coating device. In certain embodiments,the methods of the invention provide conformal coating of greater than95% of the introduced biomaterial.

In some embodiments, the viability and function of coated cells and/orcell clusters are assessed by any of a number of methods well known inthe art, e.g., MTT assay, live/dead staining, and/or (in the case ofislets) static glucose stimulation of perifusion. In some embodiments,said assessment takes place before implantation of the cells. In caseswhere the coated cells are islets, immunoprotection of the transplantedislets by conformal coating may be evaluated by, e.g., monitoring theglucose level and/or weight of the transplanted patient, and/or byhistological evaluation.

The invention further provides methods of treating a disorder in apatient, comprising the step of implanting into the patient theconformally coated biomaterial isolated by the methods referred toherein. These disorders include, but are not limited to: diabetes,hemophilia, renal failure, amyloidosis, immune system disorders,inflammations, chronic pain, arthritis, hypertension, disorders of thenervous system, metabolic disorders, endocrine disorders,lymphoproliferative disorders, myeloproliferative disorders,myelodysplastic syndromes, stem cell disorders, phagocyte disorders,histiocytic disorders, abnormalities of erythrocytes or platelets,plasma cell disorders, acute leukemias, chronic leukemias, malignancies(breast carcinoma, Ewing Sarcoma, neuroblastoma, renal cell carcinoma,etc.), hypothyroidism, hypopituitarism, hypogonadism, graft failure,graft versus host disease (GVD), veno-occlusive disease, side effectsfrom pre-transplant chemotherapy (such as excessive bleeding,infertility, and renal as well as lung and heart complications), andother disorders and diseases that would be recognized by the skilledpractitioner.

As referred to herein, the term “patient” refers to the recipient of atherapeutic treatment and includes all animals. In one embodiment, thepatient is a mammal. In a particular embodiment, the patient is human.

The conformally coated biomaterial produced by the methods of theinvention may be implanted in any appropriate place within a patient.The biomaterial may be implanted in naive or pre-vascularized sites; inphysiological or transformed sites; and within tissue and organs oradjacent to them. In certain embodiments, the implant location may be,for example, intraomental (in an omental pouch), subcutaneous,intraperitoneal, intramuscular, or renal subcapsular. In one embodiment,the implant location is subcutaneous. In some embodiments, the implantlocation is not the abdominal cavity.

In some embodiments, conformally coated biomaterial produced by themethods of the invention is placed in a device before implantation in apatient, to decrease the patient immune response and/or to prolong thesurvival of the cells. The device may be any device suitable for theimplantation of biological material in a patient, e.g., the device asdescribed in U.S. Publication No. 2006/0024276 or in U.S. PatentPublication No. 6,716,246, each of which is incorporated herein byreference in its entirety. In some embodiments, the conformally coatedbiomaterial is implanted within or adjacent to a natural or synthetic,biodegradable or non-biodegradable scaffolding substrate.

In order that this invention may be better understood, the followingexamples are set forth. These examples are for purposes of illustrationonly and are not to be construed as limiting the scope of the inventionin any manner.

EXAMPLES Example 1: Computational Model

A computational model in Comsol Multiphysics (two-level set function ofthe chemical engineering modulus) has been developed to determine theeffect of different geometrical parameters (“more focusing” and “lessfocusing” flow chamber and different injection points of the water phaseinto the oil phase) and fluid dynamic parameters (ratio between waterand oil flow rates, ratio between water and oil viscosities, andinterfacial tension between the two phases) on the transition fromdripping to jetting of the water phase, the size of the final water jet,and the total stress acting in the center of the water jet.

A 2D axisymmetric geometry has been used with two different focusingsettings: “more focusing” and “less focusing” and different waterinjection points. The mesh has been created by imposing a maximum sizeof the element in the central axis (r=0) equal to 10⁻⁵ m (FIG. 1C).

Table 1 shows the values of the different experimental fluid dynamicparameters (viscosity of oil and water phases, velocity of oil and waterphases, surface tension) and the geometry of the chamber (injectionpoint for water phase in oil and type of focusing geometry) for eachdeveloped computational model. Table 1 also indicates whether the set ofexperimental parameters chosen for each model results in jetting ordripping of the water phase within the oil phase, as well as the maximumvalues of the total radial stress.

It was not possible to run the model with the true values of the waterand oil velocities, since compilation timings would have beenunacceptable and computer memory shortage would limit compilations.Therefore, we increased by 10³ the magnitude of the velocities. Results(especially regarding values of shear stresses) are thus notrepresentative of the real values in the experimental system that isdescribed further below, but are meaningful for comparison betweendifferent conditions.

TABLE 1 max max velocity velocity viscosity viscosity oil water surfaceinjection focusing max total oil water vmax vmax tension point geometryjet or stress model η oil η water oil water σ standard/ less/ drippingTr max # (Pa*s) (Pa*s) (m/s) (m/s) (N/m) closer more J/D (dyn/cm2)  10.34 0.01 5 × 10 − 2  1 × 10 − 2 0.005 std more J   2 * 10⁶  2 0.34 0.015 × 10 − 2  1 × 10 − 2 0.005 std less D   2 * 10⁶  3 0.34 0.01 5 × 10 −2  5 × 10 − 2 0.005 std less J   2 * 10⁶  4 1.301 0.01 5 × 10 − 2  5 ×10 − 2 0.005 std less J 7.5 * 10⁶  5 1.301 0.01 5 × 10 − 2  5 × 10 − 20.005 closer less J 7.5 * 10⁶  6 1.301 0.01 5 × 10 − 2  50 × 10 − 20.005 std less J   8 * 10⁶  7 1.301 0.1 1 × 10 − 2 700 × 10 − 2 0.005std more J   6 * 10⁶  8 1.301 0.01 1 × 10 − 2 700 × 10 − 2 0.005 stdmore J   5 * 10⁶  9 1.301 0.01 1 × 10 − 2 350 × 10 − 2 0.005 std more J3.5 * 10⁶ 10 1.301 0.01 1 × 10 − 2 125 × 10 − 2 0.005 std more J 2.5 *10⁶

The results are shown in FIGS. 2A-11C.

Example 2: Flow Chamber Design and Realization

Flow chambers (with “more focusing” and “less focusing” geometry,different diameters of the co-axial chambers) have been designed andmanufactured to experimentally test the effects of different geometriesand different hydrodynamic parameters on islet encapsulation.

The flow chambers are characterized by a flow focusing region (“more”and “less” focusing) and a narrow straight channel down-stream.

The water phase containing coating solutions and cell clusters isinjected in the center channel by a catheter (FIG. 12A: 11, “morefocusing” geometry) that is connected to the injection tube and pumpthrough a male Luer integral lock ring (FIG. 12A: 10), and is focused inthe main chamber (FIG. 12A: 3) into the narrow channel downstream (FIG.12A: 4, 5, 7) from the main chamber by the co-flowing external stream ofoil that is injected within the chamber through a lateral port (FIG.12A: 9). Entrapped air is eliminated through a lateral port (FIG. 12A:8) upstream of the oil injection port. The water injection catheter(FIG. 12A: 11) is secured in its optimal position through a locking cap(FIG. 12A: 1) for the inner chamber (FIG. 12A: 2).

Oil phase flow is maintained by a peristaltic pump while water phaseflow is maintained by a 2 ml-syringe pump.

Both the “more focusing” and the “less focusing” flow chambers have beentested, with more promising results for the “more focusing” flow chamber(see design of exemplary flow chamber: FIGS. 12A and 12B).

Different injection positions of the water phase inside the oil phasehave also been tested and the optimal positions discovered to be: (1)the standard one in which the tip of the water injection needleco-localizes with the base of the focusing region of the device, and (2)a position in which the tip of the water injection needle is 0.5 mmupstream of the focusing region (FIGS. 12A and 12B).

We performed optimization experiments using islet-like beads (redpolystyrene) that have a size similar to islets (50-300 μm).

We performed experiments to determine:

-   -   optimal ratio of water versus oil velocities;    -   optimal islet-like bead concentration in the water phase;    -   optimal set-up to allow injection of the water phase within the        oil phase without having backflow of the oil phase into the        water injection needle;    -   optimal composition of the water phase to prevent cell cluster        coalescence;    -   optimal composition and pH of the water phase and oil phase to        allow gelation of coating solution downstream jet break-up;    -   optimal method for purifying PEG coated and non-coated beads and        PEG droplets from PPG oil phase at the outflow; and    -   optimal method for purifying coated beads from empty PEG beads.        The results are discussed below.

Example 3: PEG Functionalization and Gelation

PEG gelation is achieved by cross-linking of PEG 8-arm 10 kDa, which hasbeen functionalized with divinyl sulfone (PEG-dVS) or with maleimide(PEG-MAL), by addition of dithiothreitol (DTT) and by adjusting the pHfrom less than 6.5 to 7.4 using triethanolamine (TEA). Gelation ofalternative non PEG-based hydrogels (for example, VLVG) is achieved bycross-linking of monomers that have been functionalized with divinylsulfone (dVS) or with maleimide (MAL) by addition of dithiothreitol(DTT), and by adjusting the pH from less than 6.5 to 7.4 usingtriethanolamine (TEA).

A schematic on PEG functionalization with dVS (greater than 90%) byMichael type addition of dVS in the presence of NaH (1) is shown in FIG.13 .

In order to be able to image PEG gel by fluorescence microscopy, welabeled PEG-dVS with fluoresceinamine by Michael type addition in asodium carbonate buffer (1bis) (FIG. 14 ).

Example 4: Hydrodynamic and Experimental Parameters

In the flow chambers that we designed, we have optimized jet formationand break-up into islet-containing droplets in parallel with thecomputational model and empiric determinations.

The oil phase is made with polypropylene glycol (PPG) 4000 (Sigma) with10% Span80 (Sigma), with or without 0.02 or 0.2% triethanolamine (TEA)to control the polymerization rate. TEA is added to the oil bathdownstream outflows (FIG. 12A:5)

The water phase is made with 5% w/v PEG-dVS or PEG-MAL (PEG-dVS-FITCadded in a 1:10 ratio with PEG-dVS or 3000 kDa FITC dextran at 1 mg/mlwhen fluorescence labeling of PEG gel is required), 3.1 mg/ml DTT (4mole of DTT for 1 mole of PEG-dVS), 0.8% MVG (Novamatrix) and 75,000islet-like beads (polystyrene red beads) or cell clusters per ml inbuffer (HBSS without Ca²⁺ and Mg²⁺). The pH of the PEG solution has beenadjusted to be lower than 6 (5 for Peg-dVS and 3.5 for PEG-MAL).

The water phase is injected through a needle into the oil phase first at50 μl/min and then reduced to 10 μl/min. The oil phase rate is keptconstant at 3.5 ml/min while the water phase is decreased to avoid oilbackflow into the water phase injection needle, and is then keptconstant for the entire encapsulation process. Air is injected beforethe water to avoid waste of polymer and bead products and to allowstabilization of the water in oil jet.

Example 5: Encapsulated Cell Cluster Purification and Characterization

We have also optimized methods for purifying coated model beads or cellclusters from the oil phase. Coated islet-like beads or cell clustersand PEG droplets are collected from the outflow of the flow chamber intoa 50 ml conical tube containing the oil phase with 0.02% or 0.2%triethanolamine (TEA) until polymerization of the PEG coating iscompleted (between 5 and 10 minutes after the last encapsulated clusterhas reached the outlet).

The oil phase is separated from the water phase first by centrifugationfor 5 minutes at 1500 rpm in 50 ml conical tubes. Subsequently, completeremoval of PPG is achieved through hexane extraction several times (50%hexane and 50% HBSS) by centrifuging first for 5 minutes at 1500 rpm ina 50 ml conical tube and then for 1 minute at 500 gin 1.5 ml Eppendorfftubes until the oil is completely eliminated from the water phase andthe HBSS results are clear from PPG (a whitish emulsion formed by thetwo phases easily reveals PPG presence in HBSS). 50 mM CaCl₂ solution inosmotically balanced buffer is added to allow gelation of MVG.

PEG droplets can be separated from PEG-coated beads or clusters bygradient centrifugation (PEG gel has a lower density than islets) bylayering Ficoll solutions at the following densities: 1.042 g/ml andmedia. After centrifugation, coated beads or clusters will be at thebottom while empty beads will layer on top of the 1.042 g/ml layer andin the media. The supernatant is discarded and coated beads or clustersare collected and washed. PEG coating of beads or clusters can be imagedby fluorescence microscopy or by confocal microscopy if PEG-dVS-FITC or3000 kDa FITC dextran is added to the water phase.

By optimizing the experimental set-up, we improved the efficiency ofbead and cell cluster coating by PEG from 10 to 95%, achieving a goodyield of coated versus non-coated beads or clusters. Coated beads have auniform PEG coat around their volume of between about 10 and 20 μm, andthe thickness of this coating does not depend on bead size (which variesbetween 50 and 300 μm).

Confocal imaging and image processing by Imaris allows for evaluation ofthe quality of the coating, with some limitations concerning confocallaser penetration through the samples (we cannot image both sides of thecoating). FIG. 15A-D depicts some examples of confocal imaging ofFITC-PEG coated beads; left: orthogonal projection of a z-scan of theentire coated bead, right: 3D reconstruction of the z-scan series andsectioned in the mid plane.

Example 6: Optimization of Encapsulation for Coating Thickness andCompleteness Using Heterogeneous Bead Models

The characteristics of the conformal coating that we aimed to achieveare as follows: (1) high efficiency of coating (high ratio of coated vs.uncoated beads), (2) high efficiency of primary vs. secondary polymerproducts (reduce the number of empty polymer beads and the size ofsecondary products from jet break-up), and (3) high yield of coatedbeads after purification from the oil phase.

We performed several experiments in which the effect of the followingparameters as an outcome indicator were evaluated:

-   -   (a) bead concentration in the water phase (from 5,000 to 100,000        IEQ/ml),    -   (b) surfactant concentration in the water phase (to prevent bead        coalescence after coating, 0 to 2.5% Pluronic F-68,    -   (c) ratio of the flow rates of the water phase (Qw) with respect        to the oil phase (Qo) and absolute flow rate of the oil phase        (the following Qw/Qo combinations have been tested: 50        μl/min-0.5 ml/min; 50 μl/min-2.5 ml/min; 150 μl/min-0.5 ml/min,        150 μl/min-2.5 ml/min,    -   (d) design of the flow chamber (both the focusing angle of the        device that allows dripping to jet transition of the water phase        in oil and the diameter of the down-stream channel (diameter: d)        have been modified, resulting in four different device designs:        more focusing/d=1 mm; less focusing/d=1 mm; more focusing/d=3        mm; less focusing/d=3 mm), (e) position of the water phase        injection needle with respect to the focusing channel of the        device (this affects the dripping to jetting transition) (from 0        mm to 1 mm upstream of the focusing region),    -   (f) composition and setup of the outflow collection media (100%        oil phase and 0% water phase and different % triethanolamine in        oil, and magnetic stirring vs. non stirring of the collected        outflow),    -   (g) coated bead extraction from the oil phase and separation        from the secondary polymeric beads and the oil phase (addition        of different volumes of hexane solvent for oil phase removal and        different cycles of centrifugation and coated bead sedimentation        periods).

FIG. 16A-16F shows examples of coated bead morphology resulting from thedifferent combinations of the above experimental parameters. In theseexamples, FITC-PEG-dVS has been added to the water phase at 1%concentration to fluorescently label the coating and to enableevaluation of the coating efficiency.

One optimized protocol for bead coating that resulted from the aboveoptimization experiments is as follows:

-   -   Composition of the water phase: 10% PEG-dVS, 2% Pluronic F-68,        50000 IEQ/ml and 0.62% w/v of DTT in serum-free media pH 6.5;    -   Flow parameters: Qw=50 μl/min/Qo=0.5 ml/min (Qo/Qw=350 &        Vo/Vw=3.5);    -   Device design: more focusing device, d=1 mm, focusing angle of        60 degrees, injection needle 0.5 mm upstream of focusing region;    -   Outflow: 5 ml PPG with 0.02% triethanolamine stirred at 300        rpm/outflow tube into the oil phase and far from the stirring        cone; and    -   Purification: collect outflow in a 15 ml conical tube.        Centrifuge 1500 rpm/5 min. Discard all PPG. Resuspend the coated        beads and secondary polymer beads in 1 ml hexane and transfer to        a 2 ml eppendorff tube. Centrifuge 1 min/500 g. Discard hexane        supernatant. Add 0.5 ml hexane and resuspend, then add 1 ml PBS.        Centrifuge 1 min/500 g. Discard hexane/PBS supernatant.        Resuspend in 1 ml PBS. Proceed with gradient centrifugation        (described above) to purify coated beads from secondary empty        PEG beads.

Example 7: Optimization of Composition of Coating Material for desiredPermeability and Permselectivity

Depending on the application of the encapsulation technology describedhere, different values of permeability and permselectivity may beneeded. We validated existing experimental methods to assess thoseparameters in several alginate and PEG-based hydrogels. We found anegative correlation between the degree of cross-linking and the networktightness of PEG-dVS-based hydrogels and their permeability to proteinsof known molecular weight (FIG. 17A). In order to decrease the degree ofcross-linking of PEG-dVS 8-arm 10 kDa through DTT, we capped VSfunctional groups through exposure to beta-mercaptoethanol at differentmolar ratios to the functional groups (cap 0: de-functionalize 0 out of8 VS groups on the PEG; cap 2: de-functionalize 2 out of 8 VS groups onthe PEG; cap 4: de-functionalize 4 out of 8 VS groups on the PEG). Inorder to decrease the tightness of hydrogel networks, we includedalginate (MVG from Novamatrix) as a network ‘spacer’ and replaced DTTwith a longer crosslinker (PEGdiThiol 1 kDa) or used PEG-dVS 4-arms 20kDa as a monomer instead of PEG-dVS 8-arm 10 kDa. 10 kDa FITC dextranwas added at 1 mg/ml to hydrogel beads and the amount (as concentration:c) that diffused out over time was measured by fluorescence reading ofthe outer bath in which beads resided. The ratio between c and thecalculated equilibrium concentration (c_(inf)) is plotted against timeand represents the kinetic of diffusion out of 10 kDa dextran of eachhydrogel composition as compared to 1.6% MVG. For each hydrogelcomposition, permselectivity can be measured by adding proteins ofdifferent molecular weight to the hydrogel beads and measuring theconcentration of each protein in the outer batch at different timepoints. The percentage of proteins that have diffused out at higher timepoints for each protein represents the capability of each protein toselectively move through the hydrogel network. For PEG-dVS 8-arm 10 kDaand 0.8% MVG cross-linked with DTT, permselectivity can be assumed to bebetween 250 and 500 kDa (FIG. 17B).

Example 8: Optimization of Composition of Coating Material forBiocompatibility in the Desired Implant Site

Depending on the application of the encapsulation technology describedhere, different sites of implantation are desirable. Biocompatibilityfor a certain hydrogel being dependent on implant site, we haveestablished and validated a method to evaluate the biocompatibility ofdifferent hydrogel compositions in mice. We generated hydrogelmacroparticles (between 0.5 and 2 mm in size) and implanted them insterile condition within HBSS in different sites in mice and rats:subcutaneous, under the kidney capsule, epidydimal fat, intraperitoneal,in an omental pouch). Histological examination of cellular infiltratesand tissue remodeling at the biomaterial-tissue interface was evaluatedand scored to compare the biocompatibility of different materials. Wehave found that bioreactivity of PEG-dVS is greater than PEG-MAL andALG-VS, independent of the implant site (FIG. 18 ), and that thesubcutaneous and the kidney subcapsular sites are more reactive sites tobiomaterial implantation.

Example 9: Optimization of Encapsulation for Coating Completeness UsingRat Islets

The characteristics of the conformal coating that we aimed to achieveare as follows: (1) high efficiency of coating (high ratio of coated vs.uncoated islets), (2) high efficiency of primary vs. secondary polymerproducts (reduce the number of empty polymer beads and the size ofsecondary products from jet break-up), and (3) high yield of coatedislets after purification from the oil phase.

We performed several experiments in which the effect of the followingparameters as outcome indicators were evaluated:

-   -   (a) islet concentration in the water phase (from 5,000 to        100,000 IEQ/ml),    -   (b) surfactant and alginate concentration in the water phase (to        prevent islet coalescence after coating, 0 to 2.5% Pluronic F-68        and 0 to 1.6% MVG from Novamatrix),    -   (c) ratio of the flow rates of the water phase (Qw) with respect        to the oil phase (Qo) and absolute flow rate of the oil phase        (the following Qw/Qo combinations, for example, have been        tested: 50 μl/min-0.5 ml/min; 50 μl/min-2.5 ml/min; 150        μl/min-0.5 ml/min, 150 μl/min-2.5 ml/min),    -   (d) design of the flow chamber (both the focusing angle of the        device that allows dripping to jet transition of the water phase        in oil and the diameter of the down-stream channel (diameter: d)        have been modified, resulting in four different device designs:        more focusing/d=1 mm; less focusing/d=1 mm; more focusing/d=3        mm; less focusing/d=3 mm),    -   (e) position of the water phase injection needle with respect to        the focusing channel of the device (this affects the dripping to        jetting transition) (from 0 mm to 1 mm upstream of the focusing        region),    -   (f) composition and setup of the outflow collection media (100%        oil phase and 0% water phase and different % triethanolamine in        oil, and magnetic stirring vs. non stirring of the collected        outflow),    -   (g) coated islet extraction from the oil phase and separation        from the secondary polymeric beads and the oil phase (addition        of different volumes of hexane solvent for oil phase removal and        different cycles of centrifugation and coated islet        sedimentation periods).

FIG. 19A-19C shows coated islet morphology resulting from the optimalcombinations of the above experimental parameters. In these examples,FITC-PEG-dVS (FIG. 19B) or 2000 kDa FITC dextran (FIG. 19C) have beenadded to the water phase at 1% or 1 mg/ml concentration respectively tofluorescently label the coating and to enable evaluation of coatingcompleteness and efficiency.

The optimized protocol for islet coating that resulted from the aboveoptimization experiments is as follows:

-   -   Composition of the water phase: 5% PEG-dVS, 0.8% MVG        (Novamatrix), 75000 IEQ/ml and 0.31% w/v of DTT in HBSS without        Ca²⁺ and Mg²⁺ with the PEG solution at pH 5;    -   Flow parameters: Qw=10 μl/min/Qo=3.5 ml/min (Qo/Qw=350 &        Vo/Vw=3.5);    -   Device design: more focusing device, d=1 mm, focusing angle of        60 degrees, injection needle 0.5 mm upstream of focusing region;    -   Outflow: 15 ml PPG with 0.02% triethanolamine in a 50 ml conical        tube; and    -   Purification: Centrifuge 1500 rpm/5 min. Discard all PPG.        Resuspend the coated islets and secondary polymer beads in 5 ml        hexane and pipet up and down 5 times without breaking the        pellet. Add 40 ml HBSS without Ca²⁺ and Mg²⁺ and invert the tube        twice. Centrifuge 5 min/1500 rpm. Discard supernatant. Add 1 ml        HBSS without Ca²⁺ and Mg²⁺, resuspend the pellet and transfer to        a 1.5 ml Eppendorf low-binding microcentrifuge tube. Centrifuge        30 sec/500 g. Discard supernatant. Add 0.5 ml hexane and then 1        ml HBSS without Ca²⁺ and Mg²⁺ and invert the tube three times        to mix. Centrifuge 30 sec/500 g. Discard hexane/PBS supernatant.        Resuspend in 1 ml HBSS with Ca²⁺ and Mg²⁺. Centrifuge 30        sec/500 g. Discard supernatant and resuspended in basal islet        media. Plate the coated islets at 38 IEQ/cm² in petri dishes        containing full media that had been equilibrated in a 5% CO₂ and        37° C. incubator for at least 15 minutes.

Example 10: Evaluation of In Vitro Function of Encapsulated Islets as aFunction of Encapsulation Materials

The functional response (insulin release upon glucose stimulation) ofrat islets encapsulated with different hydrogel compositions has beenevaluated through a previously established method of static stimulationwith different amounts of glucose: Low1: 60 mg/dL glucose, High: 300mg/dL, Low2: 60 mg/dL. As expected, insulin response to glucosestimulation positively correlated with increased permeability of eachhydrogel coating composition (FIGS. 17A-17B and 20A-20C). Islets coatedwith PEG-dVS 8arm 10 kDa and cross-linked with DTT had better responseat lower PEG percentages and for conformal coating versus clumps androds (SPAGH) and when MVG alginate (ALG) was added to the hydrogel (FIG.20A). Islets conformally coated with PEG-dVS 8arm 10 kDa cross-linkedwith DTT showed better response than gels crosslinked with linearHS-PEG-SH, while capping PEG-VS functional groups withbeta-mercaptoethanol did not show any impressive improvement (FIG. 20B).Islets conformally coated with PEG-dVS 8arm 10 kDa cross-linked with DTTshowed better response than crosslinking with multi-arm HS-PEG-SH (4-arm10 kDa and 4-arm 20 kDa, FIG. 20C).

Example 11: Optimization of Encapsulation for Viability and In VitroFunction of Encapsulated Islets as a Function of Timing

We have evaluated the effect of timing betweenisolation/encapsulation/functional evaluation on islet viability(live/dead staining) and functional response (insulin release uponglucose stimulation) of rat islets encapsulated with 5% PEG-dVS 8arm 10kDa 0.8% MVG cross-linked with DTT (PEG ALG). Rat islets encapsulated byconformal coating two days after isolation are poorly viable right afterencapsulation and show a ring of death on the external surface. Culturein standard conditions for up to 48 hours after encapsulation allowscomplete recovery of islet viability (FIG. 21A). While the functionalresponse (insulin secretion after glucose stimulation: L1: 60 mg/dLglucose, H: 300 mg/dL, L2: 60 mg/dL) of naked islets rapidlydeteriorates during standard ex vivo culture after isolation (FIG. 21B),encapsulation through conformal coating with PEG ALG one day (FIG. 21C)or two days (FIG. 21D) after isolation and evaluated at 24 and 48 hoursafter encapsulation, is able to completely preserve islet function.

Example 12: Evaluation of In Vivo Function of Encapsulated Islets inRestoring Normoglycemia of Chemically-Induced Diabetic Mice

In vivo function of islets encapsulated through conformal coating hasbeen for their ability to restore normoglycemia in chemically-induceddiabetic immunocompetent mice following transplants of encapsulatedsyngeneic islets under the kidney capsule.

Murine (C57BL/6) islets conformally coated with PEG ALG and transplantedat 700 or 1500 IEQ/ mouse under the kidney capsule of chemically-induceddiabetic syngeneic mice rapidly reversed diabetes in recipient mice andallowed maintenance of normoglycemia for more than 100 days. Nephrectomyconfirmed that normoglycemia was due to coated islet function (FIG. 22).

Histological (FIG. 23 , left) and immunohistochemical (FIG. 23 , right)evaluation at rejection time of naked controls (top, day 11) andconformally coated (bottom, day 55) islets transplanted under the kidneycapsule of concordant xenogeneic recipients confirms that conformalcoating is able to protect islet xeno-transplants from immunedestruction without compromising their viability and metabolic function.

Example 13: Utility of Conformal Coating in Immunoisolation of IsletAllografts

Islets are isolated and conformally coated by the methods describedabove, then implanted in diabetic allogeneic hosts. The viability andfunction of the coated islets are assessed by MTT assay, live/deadstaining and by static glucose stimulation pre-implantation as describedabove to guarantee the potential of coated islets to normalize glycaemiain diabetic hosts. Immunoprotection of transplanted islets fromrejection by conformal coating is evaluated by monitoring the bloodglucose level and weight of the transplanted host and by histologicalevaluation after sacrifice.

Example 14: Utility of Conformal Coating in Immunoisolation of IsletXenografts

Islets are isolated and conformally coated by the methods describedabove, then implanted in diabetic xenogeneic hosts. The viability andfunction of the coated islets are assessed by MTT assay, live/deadstaining and by static glucose stimulation pre-implantation as describedabove to guarantee the potential of coated islets to normalize glycaemiain diabetic hosts. Immunoprotection of transplanted islets fromrejection by conformal coating is evaluated by monitoring the bloodglucose level and weight of the transplanted host and by histologicalevaluation after sacrifice.

Example 15: Scale Up of Conformal Coating Methods

In the flow chambers that we designed, the oil phase is made withpolypropylene glycol (PPG) 4000 (Sigma) with 10% Span80 (Sigma). Thewater phase is made with hydrogel solution. The water phase is injectedthrough a needle into the oil phase at 10 μl/min. The oil phase rate ismaintained at 3.5 ml/min.

Because the coating device is in a vertical configuration, the procedurecan be scaled up to guarantee conformal coating of larger humanpreparations with no variability between batches of the samepreparation. To allow encapsulation of hundreds of thousands of humanislets at the same time and with the same experimental parameters, aseries of parallel vertical chambers can be assembled in a radialconfiguration in which radial flow to each chamber feeds the water phasecontaining the islet prep to each separate chamber with comparablehydrodynamic flow characteristics. In this manner, water jet break-uphappens at the same time in each separate chamber, resulting incomparable coatings for islets coming from different channels. Coatedislets and secondary empty polymer beads are then collected in the samecontainer and purified at the same time to further reduce any potentialbatch to batch variability.

All publications and patent applications cited in this specification areincorporated herein by reference as if each individual publication orpatent application were specifically and individually indicated to beincorporated by reference.

REFERENCES

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1.-55. (canceled)
 56. A method of treating a disorder in a patient,comprising implanting into the patient a biomaterial conformally coatedby a method comprising the steps of: a) injecting a water phase within acoaxial oil phase in a coating device that allows for a transition fromdripping to jetting and flow elongation of the water phase within theoil phase; b) adding the biomaterial and the coating material to thewater phase, wherein polymerization of the coating material occursdownstream of breakup of the water phase jet into particles, resultingin the conformal coating of the biomaterial with the coating material;c) optionally collecting the outflow of the coating device; d)optionally purifying the conformally coated biomaterial andbiomaterial-free coating material from the oil phase; and e) optionallyseparating the conformally coated biomaterial from the biomaterial-freecoating material; wherein the biomaterial comprises cells or cellclusters.
 57. The method of claim 56, wherein said disorder is diabetes.58. The method of claim 56, wherein said conformally coated biomaterialcomprises islet cells or cell clusters.
 59. The method of claim 56,wherein the conformally coated biomaterial comprises polyethylene glycol(PEG).
 60. The method of claim 56, wherein: a) the water phase comprises75,000 islet cells/ml, and further comprises: i) 10% PEG, 2%Pluronic-F68, and 0.62% w/v DTT in serum-free media at pH 6-7; ii) 5%PEG, 1% Pluronic-F68, and 0.31% w/v DTT in HBSS at pH 6-7; iii) 5% PEG,1% Pluronic-F68, 0.8% medium viscosity G-groups alginate and 0.31% w/vDTT in HBSS without Ca²⁺ and Mg²⁺ at pH 6-7; or iv) 5% PEG, 0.8% mediumviscosity G-groups alginate and 0.31% w/v DTT in HBSS without Ca²⁺ andMg²⁺ at pH 6-7; and b) the oil phase comprises PPG with 10% Span80,wherein said oil phase further optionally comprises 0.02 or 0.2%triethanolamine.
 61. The method of claim 56, wherein the coating devicecomprises a flow chamber comprising a flow focusing region and a channeldownstream of the flow focusing region; and wherein the flow chamber hasat least one of the following properties: a) the diameter of the innerchannel of the flow focusing region is restricted from 10d to d alongits length, wherein d is about 1 mm; b) the focusing angle of the flowfocusing region is about 60 degrees; c) the channel downstream of theflow focusing region is 1 mm in diameter; and d) the water phase isinjected into the flow chamber through a needle or a catheter whose tipis localized about 0.5 mm upstream of the focusing region.
 62. Themethod of claim 56, wherein the coating method has at least one of thefollowing properties: a) the ratio of the oil phase velocity to thewater phase velocity is 350; b) the ratio of the oil phase viscosity tothe water phase viscosity is 3.5, 130, or 13; c) the water phase isinjected into the oil phase first at 50 μl/min and then reduced to 10μl/min, while the oil phase is maintained at 3.5 ml/min; and d) air isinjected into the oil phase before injection of the water phase.
 63. Themethod of claim 56, wherein the step of purifying the conformally coatedbiomaterial and biomaterial-free coating material from the oil phasecomprises the steps of: a) centrifuging the coating device outflow toseparate the oil phase from the conformally coated biomaterial andbiomaterial-free coating material; and b) optionally performing hexaneextraction until the oil phase is completely eliminated from theconformally coated biomaterial and biomaterial-free coating material.64. The method of claim 56, wherein the step of separating theconformally coated biomaterial from the biomaterial-free coatingmaterial is performed by gradient centrifugation or by settlement ofcoated clusters by gravity.
 65. The method of claim 56, wherein: a) saidwater phase comprises 5% PEG, 0.8% MVG, 75,000 islet cells/ml, and 0.31%w/v DTT in HBSS without Ca²⁺ and Mg²⁺ at pH 6-7; b) said oil phasecomprises PPG with 10% Span80, wherein said oil phase optionallycomprises 0.02% or 0.2% triethanolamine; and c) said coating devicecomprises a flow chamber comprising a flow focusing region with achannel whose inner diameter is reduced from 10 mm to 1 mm with afocusing angle of 60 degrees, and a channel downstream of the flowfocusing region that is about 1 mm in diameter.
 66. The method of claim56, wherein: a) said coating method comprises the steps of: i) applyingthe oil phase to the flow chamber; ii) optionally injecting air into theflow chamber through a catheter whose tip is localized 0.5 mm upstreamof the base of the focusing region; and iii) injecting the air, ifpresent, and the water phase into the flow chamber through saidcatheter, wherein the water phase is first injected at 50 μl/min andthen reduced to 10 μl/min, while the oil phase is maintained at 3.5ml/min, such that the surface tension between the water and the oilphase causes the water jet to break up into microliter dropletscomprising the conformally coated biomaterial and biomaterial-freecoating material; and b) said coating method optionally furthercomprises the steps of: iv) collecting the outflow from the flowchamber; v) centrifuging the outflow to separate the conformally coatedbiomaterial and biomaterial-free coating material from the oil phase;vi) removing the oil phase supernatant from the conformally coatedbiomaterial and biomaterial-free coating material; vii) resuspending theconformally coated biomaterial and biomaterial-free coating material ina composition comprising hexane; viii) centrifuging the mixture of stepvii) to separate the conformally coated biomaterial and biomaterial-freecoating material from the hexane; ix) removing the hexane supernatant;x) resuspending the conformally coated biomaterial and biomaterial-freecoating material in a composition comprising hexane and a buffer(without Ca²⁺ and Mg²⁺); xi) centrifuging the mixture of step x) toseparate the conformally coated biomaterial and biomaterial-free coatingmaterial from the hexane and buffer (without Ca²⁺ and Mg²⁺); xii)removing the hexane/buffer supernatant; and xiii) resuspending theconformally coated biomaterial and biomaterial-free coating material inbuffer containing Ca²⁺ and Mg²⁺; and c) said coating method optionallyfurther comprises the steps of: xiv) layering solutions to form adensity gradient capable of separating the conformally coatedbiomaterial and the biomaterial-free coating material; xv) applying theconformally coated biomaterial and biomaterial-free coating material tothe density gradient; xvi) centrifuging the density gradient to separatethe conformally coated biomaterial from the biomaterial-free coatingmaterial; and xvii) removing the supernatant containing thebiomaterial-free coating material.
 67. The method of claim 56, whereinthe coating method has at least one of the following properties: a)greater than 95% of the conformally coated biomaterial is purified fromthe biomaterial-free coating material; b) the conformal coating aroundthe biomaterial ranges from 10-20 μm in thickness; and c) greater than90% of the biomaterial introduced into the coating device is conformallycoated.